Cable organization assemblies
Preferred assemblies are directed to a cable assembly that includes a first electrical wire and a second electrical wire; with a thermo-resistant material that is molded around the wires. Zipper teeth are molded to the thermo-resistant material of both of the wires. The zipper teeth on the first wire are releasably attached to the zipper teeth on the second wire, and at least one reinforcing fiber is encapsulated with one of the wires.
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This application claims priority to pending Provisional Application No. 61/292,981 “Cable Organization Assemblies” to Groset, filed Jan. 7, 2010, which is expressly incorporated by reference herein in its entirety.
FIELD OF THE INVENTIONThe embodiments herein relate to assemblies that are configured to prevent cables from becoming entangled with each other. More specific embodiments relate to two or more cables that are configured to be releasably coupled to one another. Embodiments herein can be used to prevent entanglement of audio wires, such as headphone wires and stereo speaker wires, in addition to other suitable cables.
BACKGROUNDMultiple electronic devices are designed to be used with a plurality of connecting wires and cables. Common examples include audio or video players that have a headphone jack, or have ports for speaker wires. A common problem for users is that these cables often become entangled with each other. For example, left and right headphone wires readily become intertwined and knotted, especially in ear bud style headphones. Additionally, stereo speaker wires usually are configured in pairs and can also become entangled with themselves or other wires.
There have been prior attempts to resolve this issue. European Patent Application 1509062 A1 to Fung (hereinafter “Fung”) discloses a sliding mechanism that is integrated directly into the cables, see
It is thus one embodiment herein to provide cable assemblies that include means for preventing entanglement and easily allow the incorporation of a zipper or other releasable connection means to the cables.
SUMMARYAccording to preferred embodiments, the teachings herein are directed to cable assemblies comprising a first and second wire individually encapsulated in an outer layer comprising a thermo-resistant material, wherein the first and second outer layers each comprise means for releasably attaching with each other.
Further embodiments are directed to methods of making cable assemblies comprising: (a) providing a first and second wire individually encapsulated in an outer layer comprising a thermo-resistant material; and (b) affixing means for releasable attachment on the outer layers of the first and second wires, such that the outer layers can releasably attach with one another.
It will be appreciated that the drawings are not necessarily to scale, with emphasis instead being placed on illustrating the various aspects and features of embodiments of the invention, in which:
Embodiments of the present invention are described below with reference to the above described Figures. It is, however, expressly noted that the present invention is not limited to the embodiments depicted in the Figures, but rather the intention is that modifications that are apparent to the person skilled in the art and equivalents thereof are also included. In general embodiments the assemblies herein include at least two cables (80a, 80b) that are capable of releasable attachment. Further embodiments can also manage 3, 4, 5, 6, 7, 8, 9, 10 or more cables.
Earphone Cable Assemblies
More specifically, the two cables 80a and 80b each can include an outer layer or over-mold 60a and 60b that is made of rubber or other flexible material which can be incorporated using any suitable method including cast or injection molding, for example. The over-mold 60a and 60b makes it simpler for manufacturing the assemblies herein as it can easily encapsulate the wires. Other suitable flexible materials for the over-mold can include fabric, plastic, and foam. As shown in cross-sectional view of
According to certain embodiments, such as when a zipper is utilized, it is preferred that the means for releasable attachment do not traverse the entire length of the cables 80a and 80b as measured from the stop 70 or jack 90 to the earphones 10a and 10b. Partial traversal prevents the zipper teeth 40a and 40b from painfully contacting or pinching the user's face or neck. To prevent this hazard, the assembly 100 can include a non-teethed section 20a and 20b. Alternatively, the over-mold can simply end before the earphones 10a and 10b (such as at sections 30a and 30b) and the headphone wire casing 120a and 120b can simply be exposed for a portion of their length.
In optional embodiments, the outer layer 60a and 60b can include ribs 110a and 110b. Ribs 110a and 110b which provide protrusions and recessions along the length of the outer molding 60a and 60b can be used to achieve better flexibility and weight reduction. In general, the ribbing 110a and 110b removes material which reduces weight from the overmold 60a and 60b and allows for better manipulation of the assembly 100.
The cables 80a and 80b can include non-ribbed sections without means for releasable connection (e.g., zippers) 20a and 20b and ribbed sections 30a and 30b that lack means for releasable attachment, depending on the specific design goals. According to further embodiments the material that constitutes the outer layer 60a and 60b can be used for non-teethed sections 20a and 20b and the stop 70.
The bottom end of the zipper can include a means for stopping the zipper so the cables 80a and 80b do not become completely disengaged. As shown in
For manufacturing the assembly 100 a mold can be configured to encapsulate the headphone wires 130a and 130b up to the earphones 10a and 10b if desired. Alternatively, the mold can be configured such that the over-mold ends before the earphones 10a and 10b and the headphone wire casing 120a and 120b can simply be exposed for a portion of their length. The zipper backing material 140a and 140b can then be wrapped around the headphone wire casings 120a and 120b and placed into the mold. Rubber, or other suitable materials can be added to the mold and allowed to harden to form the final assembly.
As the releasable attachment means described herein add additional weight to headphone wires 20a and 20b by themselves, further embodiments include the use of means to prevent the earphones 10a and 10b from falling downward quickly when taken out of a user's ears. Complementary oppositely charged magnets 210a and 210b, or other means for releasable attachment can be used either on or near the earphones 10a and 10b, such as in the non-teethed region 20a and 20b, for example. As shown in
A third embodiment of a zipper earphone cable assembly 700 is shown in
The assemblies herein, including the third earphone zipper embodiment 700 can optionally include a volume control 1000 positioned on the first cable 80a above the zipper teeth 40a. The volume control 1000 is operably coupled to the internal wiring of the cable 80a and includes an external control mechanism accessible by the user configured to increase/decrease volume and/or completely mute volume such that no significant audio signal is transmitted to the ear buds 10a and 10b. The volume control 1000 can also be positioned on the second cable 80b.
As shown in
An inner layer 902 can also be used, preferably a material having elastic properties such as a thermoplastic elastomer (TPE) and more specifically an extruded TPE, which include copolymers or a physical mix of polymers (usually a plastic and a rubber) which consists of materials with both thermoplastic and elastomeric properties. Reinforcement fibers 908 can also be used to add strength to the cables 80a and 80b as fabrication and function can involve higher pull strength than conventional earphone cables. Preferred materials include aramids such as Kevlar, and more specifically 200D-400D Kevlar including, 200D Kevlar, 300D Kevlar, and 400D Kevlar. Audio wires 904 configured to transmit sound from the jack 90 to the earbuds 10a and 10b can be positioned within the cables 80a and 80b. Preferred audio wires 904 include copper wires which can also be surround by an insulating material 906 such as nylon silk. Using the teachings herein one can manufacture a zipper earphone cable assembly 700 that withstands at least up to 15 kg of torque from end to end (earbud 10a to jack 90).
Once positioned as desired in the mold 702 the heated liquid material is allowed into the mold 702 such that it surround the cables 80a and 80b and fills the teeth shaped cavities 704a and 704b. After being allowed to set, the resulting assembly as shown in
As shown in
In addition to standing alone, the zipper earphone assemblies herein can alternatively also be utilized directly with a clothing article, such as on a zip-up jacket or sweatshirt. The zippered cabled assembly can be manufactured according to the teachings described herein and then attached to the clothing article by sewing or other fastening means including hook and loop fasteners, clips, snaps, and the like. Preferably the audio jack can either be exposed at the bottom of the zipper or be positioned within a pocket of the clothing article such that a user can attach it to a portable audio player. According to one embodiment both cables of a headphone assembly have zipper teeth attached to them according to the teachings herein and define a zipper of an article of clothing, such as a jacket or sweatshirt.
Preferably water resistant, heat resistant, and durable ear buds and other parts are utilized to protect against the water from a clothes washer and the heat from a clothes dryer. Water proof ear buds are known in the art and can readily be used with this embodiment. According to certain embodiments, thermo-resistant thermoplastics such as POM or polycarbonate (pc) and the like can be used for the casing, while a hydrophobic mesh or membrane can be used for the venting. Additionally a high temperature resistant material such as polyetherimide (PEI), polyether ether ketone (PEEK) Polyethylene terephthalate (PET) can be used as a diaphragm material.
In certain non-preferred embodiments, the ear buds can be only water proof and the clothing article can include instructions not to machine dry, for example. Thus a user could wash their clothing article with the incorporated water proof ear buds and then hang it out to dry as opposed to subjecting it to the heat associated with a clothes dryer.
An additional non-zippered cable assembly 400, such as shown in
Expandable Cable Management Systems
According to additional embodiments, the cable management systems herein are not necessarily used with earphone wires and can be used to prevent entanglement of additional type of cables.
Similarly
Additional embodiments are directed to using fabric having 1 or more channels as an outer layer to cover the two or more wires for certain embodiments above. Fabric is a preferred choice for certain designs in that it is very light weight and highly flexible. More specifically a zipper backing material, such as AQUAGUARD® manufactured by YKK® can be used to cover and manage wires utilizing the above embodiments, depending on the desired properties of the cable management assembly. This embodiment makes it easier to incorporate a zipper as a means for releasable attachment between the two cables.
The invention may be embodied in other specific forms besides and beyond those described herein. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting, and the scope of the invention is defined and limited only by the appended claims and their equivalents, rather than by the foregoing description.
Claims
1. A cable assembly comprising:
- a first electrical wire;
- a second electrical wire; a thermo-resistant material that is molded around the first electrical wire and around the second electrical wire;
- zipper teeth that are molded to the thermo-resistant material of the first electrical wire and the second electrical wire;
- the zipper teeth molded to the first electrical wire being releasably attached to the zipper teeth molded to the second electrical wire; and
- at least one reinforcing fiber, the at least one reinforcing fiber being encapsulated with at least one of the first electrical wire and the second electrical wire.
2. The cable assembly of claim 1, wherein:
- the zipper teeth are created by injection molding; and
- the cable assembly is a headphone assembly and the first and second wires are configured to transmit audio sound from a jack to headphones.
3. The cable assembly of claim 1, wherein an outer surface of the first electrical wire and the second electrical wire comprise at least one of draw textured yarn and braided nylon.
4. The cable assembly of claim 1, wherein the zipper-teeth are thermoplastic.
5. The cable assembly of claim 1, wherein the at least one reinforcement fiber comprises an aramid.
6. The cable assembly of claim 1, wherein the at least one reinforcement fiber comprises Kevlar.
7. The cable assembly of claim 2, wherein the cable assembly can withstand up to 15 kg of torque from the jack to the headphones.
8. The cable assembly of claim 1, wherein the cable assembly further includes a stop to help stop a zipper slider from sliding off the bottom of the zipper teeth, wherein the stop is attached to the first electrical wire and the second electrical wire.
9. A method of making a cable assembly comprising:
- providing a first electrical wire and a second electrical wire that are individually encapsulated by injection molding, an outer layer comprising a thermo-resistant material outside the first electrical wire and the second electrical wire;
- an affixing apparatus for releasable attachment on the outer layers of the first electrical wire and the second electrical wire, such that the outer layers can releasably attach with one another; and
- one or more reinforcement fibers positioned within the injection molding individually encapsulating the first electrical wire and the second electrical wire.
10. The method of claim 9, wherein the cable assembly is a headphone assembly and the first and second wires are configured to transmit audio sound from a jack to headphones.
11. The method of claim 10, wherein the thermo-resistant material comprises at least one of draw textured yarn and braided nylon.
12. The method of claim 10, wherein the cable assembly can withstand up to 15 kg of torque from the jack to the headphones.
13. The method of claim 10, wherein a volume control is attached to at least one of the first electrical wire and the second electrical wire.
14. The method of claim 9, wherein the affixing apparatus comprises a thermoplastic zipper.
15. The method of claim 14, wherein a stop used to stop a zipper slider from sliding off the bottom of the zipper, wherein the stop is attached to both the first and second electrical wires.
16. The method of claim 9, wherein the first and second wires are individually encapsulated in an inner layer having thermo-resistant and elastomeric properties positioned underneath the outer layer.
17. The method of claim 9, wherein the one or more reinforcement fibers comprise at least one of an aramid and Kevlar.
18. A cable assembly comprising:
- a first electrical wire;
- a second electrical wire;
- a thermo-resistant material that is molded around the first electrical wire and around the second electrical wire;
- zipper teeth that are molded to the thermo-resistant material of the first electrical wire and the second electrical wire;
- the zipper teeth molded to the first electrical wire being releasably attached to the zipper teeth molded to the second electrical wire via a zipper slider;
- at least two reinforcing fibers comprising a first reinforcing fiber and a second reinforcing fiber, the first reinforcing fiber being encapsulated with the first electrical wire, the second reinforcing fiber being encapsulated with the second electrical wire; and
- a stop used to stop the zipper slider from sliding off a bottom of the zipper teeth, the stop being attached to the first electrical wire and the second electrical wire, wherein the cable assembly is a headphone assembly, and the first electrical wire and the second electrical wire are configured to transmit audio sound from a jack to headphones.
19. The cable assembly of claim 18, further comprising a volume control attached to at least one of the first electrical wire and the second electrical wire.
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Type: Grant
Filed: Nov 8, 2010
Date of Patent: Jun 4, 2013
Patent Publication Number: 20110162883
Assignee: Zipbuds, LLC (San Diego, CA)
Inventors: Erik Groset (Carlsbad, CA), Justin Liu (San Diego, CA), Michael Klasco (Richmond, CA), Robin DeFay (Poway, CA)
Primary Examiner: William H Mayo, III
Application Number: 12/941,943
International Classification: H01B 11/06 (20060101);